In the modern day and age where automobiles are an essential part of our day to day life, the requirements of each are different. Some demand for a high-performance machine whereas others require a comfortable ride. The modern engineering helps in achieving all the aspects of a safe, reliable and fast vehicle. With the change in time, the need for an all-terrain vehicle has gradually increased. The research paper includes the optimisation of wheel assembly for better stability, comfort ride along with better handling. The analysis and simulation are done to obtain a better wheel assembly which can provide the best in class arrangements for the customer. The research mainly focused on the wheel hub, wishbones and knuckle. The designs provide the sturdiness and durability which is the primary requirement for an all-terrain vehicle. The key focus is given to material selection which provides durability and comfort. The material is inexpensive which presents an edge for the market competition as well as is value for money for the customer point of view. The Static load on wheel hub is calculated and analysed for elucidating the characteristics. The material EN-24 provides better machinability and welding applications making it more suitable for mass production.

1. International Journal of Advanced Engineering, Management and Science (IJAEMS) [Vol-2, Issue-4, April- 2016]
Infogain Publication (Infogainpublication.com) ISSN: 2454-1311
www.ijaems.com Page | 83
Suspension Assembly of BAJAATV
Aditya Pratap Singh,Rajesh Pandey,Pratik Jaiswal, Nikit Gupta,Mohit Bhandwal
Department of Mechanical and Automation Engineering, Amity University, Noida, Uttar Pradesh
Abstract— In the modern day and age where automobiles
are an essential part of our day to day life, the
requirements of each are different. Some demand for a
high-performance machine whereas others require a
comfortable ride. The modern engineering helps in
achieving all the aspects of a safe, reliable and fast
vehicle. With the change in time, the need for an all-
terrain vehicle has gradually increased. The research
paper includes the optimisation of wheel assembly for
better stability, comfort ride along with better handling.
The analysis and simulation are done to obtain a better
wheel assembly which can provide the best in class
arrangements for the customer. The research mainly
focused on the wheel hub, wishbones and knuckle. The
designs provide the sturdiness and durability which is the
primary requirement for an all-terrain vehicle. The key
focus is given to material selection which provides
durability and comfort. The material is inexpensive which
presents an edge for the market competition as well as is
value for money for the customer point of view. The Static
load on wheel hub is calculated and analysed for
elucidating the characteristics. The material EN-24
provides better machinability and welding applications
making it more suitable for mass production.
Keywords— suspension, knuckle, material.
I. INTRODUCTION
Off-road vehicles especially single seater buggy’s can
have a lot of versatility in them and can be optimized as
per requirements. The bound and travel of the wheels can
make the ride of the ATV comfortable or agile as per
requirement or both. We have used materials like EN24
and SS302 for making the required design according to
the set specifications. The specifications derived by wheel
travel, track width, steering effort and wheelbase.
Previously other researchers have focused on weight
optimization and camber, caster adjustment methods, and
we focus on sturdiness and optimization as per required
need. The calculations and analysis are done to attain the
wheel assembly which provides safety, sturdiness as well
as comfort. Our research consists of the optimisation of
understeer geometry for better handling and security
according to conditions. The design can withstand the
consistent angular velocity and dynamic angular
acceleration varied because of the all-terrain conditions.
II. DESIGN
A simple wheel assembly comprises of the following
parts:
Hub
The Hub interacts directly to the Rim of the Wheel, and
the PCD of the Hub should match that of the rim to fit
perfectly, the hub made in such a way that it can
withstand the high amount of impact and yet absorb
vibrations. Material for the Hub was selected as EN24.the
hub faces many static and dynamic loads varied because
of the conditions. The chosen material provides the
suitable Elongation with ease in machining and weld
ability.
Structural Analysis of Hub
Knuckle
Knuckle is the Hinge point of the A-arms, and the
mounting of the disc and callipers, done on it. Knuckle is
the most important part of the wheel assembly as it
governs the travel and the mounting of the A-arms. It
consists of attachments which join the entire wheel
assembly. Hence, it plays the most important role in the
assembly and faces various static and dynamic loads. The
material requires elongation, the higher capability to meet
yield stress. The material is capable of withstanding shock
loads and has enough tensile stress. It also retains good
impact properties even at a high temperature, making it
suitable for the vehicle.
Bearing
Bearing connects the hub and knuckle while providing the
rotatory movement of the wheel. The bearing provides the
stability for movement and provides the uniaxial motion.
Disc-Brake
We have added disc brakes on all four of our wheels as it
provides better braking traction and stopping distance.
The disc brake consists of the pads which with the help of
callipers provides friction and contributes to retard or to

2. International Journal of Advanced Engineering, Management and Science (IJAEMS)
Infogain Publication (Infogainpublication.com
www.ijaems.com
halt the vehicle.The energy of motion converted into
heat.The disc brakes made of cast iron but by sintering the
disc, quality is improved so that it helps to provide better
durability.As sintering is just below the melting
temperature, it helps to improve the quality and to lead to
efficiency of the disc.
Structural Analysis of Disc
Calliper
Calliper mounting on the knuckle plays an important role
as the forces on the calliper are maximum during panic
braking.
Wheel Positions
Lotus Shark Software was used to calculate the primary
mounting points of the A-Arms on the knuckle; the
present values fed in the Lotus shark software.
Front and Rear mountings
Wheel Base Parameters
Front A-Arm
As per the Software for maximum rebound required by
us, the Upper A-Arm should be 10” from the End of End
and 7” apart A- the shape of the Wishbones was
incorporated as this is most feasible for our knuckle
designs, manufacturability, and wheel travel.
EN19 EN24
Yield Stress 700 N/mm2
680 N/mm
Elongation 9% 13%
Machinability Good Medium
Weld ability Good Good
International Journal of Advanced Engineering, Management and Science (IJAEMS)
Infogainpublication.com)
halt the vehicle.The energy of motion converted into
heat.The disc brakes made of cast iron but by sintering the
disc, quality is improved so that it helps to provide better
durability.As sintering is just below the melting
improve the quality and to lead to
Structural Analysis of Disc
Calliper mounting on the knuckle plays an important role
as the forces on the calliper are maximum during panic
e was used to calculate the primary
he knuckle; the
fed in the Lotus shark software.
Front and Rear mountings
As per the Software for maximum rebound required by
Arm should be 10” from the End of End
the shape of the Wishbones was
incorporated as this is most feasible for our knuckle
bility, and wheel travel.
Front Lower Wishbone
Front Upper Wishbone
According to the Lotus Shark software, the front Knuckle
was designed, and the top Mounting is attained to be
15mm more than the bottom’s centre as it has to support
the unequal length of the A-Arm.
Knuckle Design and dimensions
Various Materials are available for manufacturing, but
major considerations are manufacturability, strength and
market availability.
Material Selection
EN24 was selected for the majority of the manufacturing
of the knuckle and hub, as it has good elongation point
and is easy to machine and weld thus proving ideal for
our work process, it highly wears resistant and can abs
high amplitude of vibrations thus giving us large field of
the area to work.
Specification Front
Wheel Travel 6”
Track width 54”
Wheel Base 58”
AL7075
680 N/mm2
740 n/mm2
17%
Medium Medium
None
[Vol-2, Issue-4, April- 2016]
) ISSN: 2454-1311
Page | 84
Front Lower Wishbone
Front Upper Wishbone
According to the Lotus Shark software, the front Knuckle
was designed, and the top Mounting is attained to be
15mm more than the bottom’s centre as it has to support
Arm.
Knuckle Design and dimensions
Various Materials are available for manufacturing, but
major considerations are manufacturability, strength and
Material Selection
EN24 was selected for the majority of the manufacturing
of the knuckle and hub, as it has good elongation point
and is easy to machine and weld thus proving ideal for
our work process, it highly wears resistant and can absorb
high amplitude of vibrations thus giving us large field of
Rear
3.5”
58”

3. International Journal of Advanced Engineering, Management and Science (IJAEMS)
Infogain Publication (Infogainpublication.com
www.ijaems.com
halt the vehicle.The energy of motion converted into
heat.The disc brakes made of cast iron but by sintering the
disc, quality is improved so that it helps to provide better
durability.As sintering is just below the melting
temperature, it helps to improve the quality and to lead to
efficiency of the disc.
Structural Analysis of Disc
Calliper
Calliper mounting on the knuckle plays an important role
as the forces on the calliper are maximum during panic
braking.
Wheel Positions
Lotus Shark Software was used to calculate the primary
mounting points of the A-Arms on the knuckle; the
present values fed in the Lotus shark software.
Front and Rear mountings
Wheel Base Parameters
Front A-Arm
As per the Software for maximum rebound required by
us, the Upper A-Arm should be 10” from the End of End
and 7” apart A- the shape of the Wishbones was
incorporated as this is most feasible for our knuckle
designs, manufacturability, and wheel travel.
EN19 EN24
Yield Stress 700 N/mm2
680 N/mm
Elongation 9% 13%
Machinability Good Medium
Weld ability Good Good
International Journal of Advanced Engineering, Management and Science (IJAEMS)
Infogainpublication.com)
halt the vehicle.The energy of motion converted into
heat.The disc brakes made of cast iron but by sintering the
disc, quality is improved so that it helps to provide better
durability.As sintering is just below the melting
improve the quality and to lead to
Structural Analysis of Disc
Calliper mounting on the knuckle plays an important role
as the forces on the calliper are maximum during panic
e was used to calculate the primary
he knuckle; the
fed in the Lotus shark software.
Front and Rear mountings
As per the Software for maximum rebound required by
Arm should be 10” from the End of End
the shape of the Wishbones was
incorporated as this is most feasible for our knuckle
bility, and wheel travel.
Front Lower Wishbone
Front Upper Wishbone
According to the Lotus Shark software, the front Knuckle
was designed, and the top Mounting is attained to be
15mm more than the bottom’s centre as it has to support
the unequal length of the A-Arm.
Knuckle Design and dimensions
Various Materials are available for manufacturing, but
major considerations are manufacturability, strength and
market availability.
Material Selection
EN24 was selected for the majority of the manufacturing
of the knuckle and hub, as it has good elongation point
and is easy to machine and weld thus proving ideal for
our work process, it highly wears resistant and can abs
high amplitude of vibrations thus giving us large field of
the area to work.
Specification Front
Wheel Travel 6”
Track width 54”
Wheel Base 58”
AL7075
680 N/mm2
740 n/mm2
17%
Medium Medium
None
[Vol-2, Issue-4, April- 2016]
) ISSN: 2454-1311
Page | 84
Front Lower Wishbone
Front Upper Wishbone
According to the Lotus Shark software, the front Knuckle
was designed, and the top Mounting is attained to be
15mm more than the bottom’s centre as it has to support
Arm.
Knuckle Design and dimensions
Various Materials are available for manufacturing, but
major considerations are manufacturability, strength and
Material Selection
EN24 was selected for the majority of the manufacturing
of the knuckle and hub, as it has good elongation point
and is easy to machine and weld thus proving ideal for
our work process, it highly wears resistant and can absorb
high amplitude of vibrations thus giving us large field of
Rear
3.5”
58”

4. International Journal of Advanced Engineering, Management and Science (IJAEMS) [Vol-2, Issue-4, April- 2016]
Infogain Publication (Infogainpublication.com) ISSN: 2454-1311
www.ijaems.com Page | 86
ability material. The Static load on wheel hub is
calculated and analysed for elucidating the characteristics.
The calculations and analysis are good enough to attain
the wheel assembly which provides safety, sturdiness as
well as comfort. Our research consists of the optimisation
of understeer geometry for better handling and security
according to conditions.
REFERENCES
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ATV,International Journal of Mechanical
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[3] Pal Arindam, Sharma Sumit, Jain Abhinav,Naiju
C.D.(2013), Optimized Suspension Design of an off
road vehicle.
[4] The International Journal of Engineering andScience
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Divyanshu (2012), Simulation of an
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(IJERA), Vol. 2, pp. 126-128
[5] S. Sarip, “Design Development of Lightweight Disc
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[6] Guru Murthy Nathil, T N Charyulu, “Coupled
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